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Please visit Tregaskiss.com for the most up-to-date information. Additional Material – For additional support materials such as spec sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Tregaskiss.com. Scan this QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport...
TABLE OF CONTENTS DECLARATION OF CONFORMITY SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING 1-1 Symbol Usage 1-2 Arc Welding Hazards 1-3 California Proposition 65 Warnings 1-4 Principal Safety Standards 1-5 EMF Information SECTION 2 — CONSIGNES DE SÉCURITÉ — LIRE AVANT UTILISATION 2-1 Symboles utilisés 2-2 Dangers relatifs au soudage à l'arc 2-3 Proposition californienne 65 avertissements 2-4 Principales normes de sécurité 2-5 Informations relatives aux CEM SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR 3-1 Uso de símbolos 3-2 Peligros en soldadura de arco 3-3 Advertencias de la Proposición 65 del estado de California...
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7-5 Changing the Power Pin or AutoLength™ Pin 7-6 Changing the Replaceable Unicable 7-7 Replacing the Wire Brake SECTION 8 — TECHNICAL DATA 8-1 Wiring Diagram 8-2 Center of Mass Coordinates SECTION 9 — PARTS LIST SECTION 10 — TROUBLESHOOTING 10-1 Troubleshooting Table ADDITIONAL SUPPORT MATERIALS OM-CA3-2.2...
DECLARATION OF CONFORMITY for European Community (CE marked) products Tregaskiss, 2570 North Talbot Rd., Oldcastle, Ontario N0R 1L0 Canada declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number Tregaskiss TOUGH GUN CA3 Series...
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING Replace worn, damaged, or cracked guns or cables. Protect yourself and others from injury – read, follow, Turn off welding power source before changing contact tip or and save these important safety precautions and gun parts. ...
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Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and WELDING WIRE can injure. sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Keep hands and body away from gun tip when Wear approved safety glasses with side shields under your trigger is pressed. helmet. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. READ INSTRUCTIONS. Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing Read and follow all labels and the Owner's such as leather gloves, heavy shirt, cuffless trousers, high Manual carefully before installing, operating, shoes, and a cap. or servicing unit. Read the safety information at the beginning of the Manual and in each section. Use only genuine replacement parts from the manufacturer. HOT PARTS can burn. Perform installation, maintenance, and service according to the Owner's Manuals, industry standards, and national, state, ...
1-3 California Proposition 65 Warnings WARNING: This product can expose you to chemicals For more information, go to www.P65Warnings.ca.gov. including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. 1-4 Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standard for Fire Prevention During Welding, Cutting, and Other Hot Standards Institute. Website: www.ansi.org.
SECTION 2 — CONSIGNES DE SÉCURITÉ — LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et UN CHOC ÉLECTRIQUE peut tuer. au mode opératoire.
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Lire et comprendre les fiches de données de sécurité et les Avertir les personnes à proximité au sujet du danger inhérent instructions du fabricant concernant les adhésifs, les au bruit. revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. LES FILS DE SOUDAGE peuvent provoquer L'ACCUMULATION DE GAZ risquent de des blessures.
2-3 Proposition californienne 65 avertissements AVERTISSEMENT – Ce produit peut vous exposer à des Pour plus d’informations, consulter www.P65Warnings.ca.gov. produits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction 2-4 Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National ...
SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR Protéjase usted mismo y a otros contra lesiones — lea, cumpla y conserve estas importantes UNA DESCARGA ELÉCTRICA puede matarlo. precauciones de seguridad e instrucciones de utilización. Siempre use guantes aislantes secos. ...
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EL AMONTONAMIENTO DE GAS puede El ALAMBRE de SOLDAR puede causarle enfermarle o matarle. heridas. Mantenga las manos y el cuerpo lejos del tubo Cierre el suministro de gas comprimido de contacto de la antorcha cuando se haya cuando no lo use. presionado el gatillo. Siempre dé ventilación a espacios cerrados o use un respirador aprobado que reemplaza el aire. LEER INSTRUCCIONES.
3-3 Advertencias de la Proposición 65 del estado de California ADVERTENCIA: Este producto puede exponerlo a químicos, Para obtener más información, acceda a incluso plomo, que el estado de California conoce como www.P65Warnings.ca.gov. causantes de cáncer, defectos de nacimiento u otros daños reproductivos. 3-4 Estándares principales de seguridad Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National ...
(3) Products which have not been operated, maintained, and repaired pursuant to Product documentation provided by Tregaskiss. Purchaser shall pay Tregaskiss for all warranty claim costs incurred by Tregaskiss (including inspection, labor, parts, testing, scrap and freight) due to warranty claims submitted by Purchaser which are not covered by Tregaskiss’...
SECTION 5 — SPECIFICATIONS 5-1 System Components Robotic MIG Gun for GMAW Welding Duty Cycle Rating: 100%: 385 amps with Mixed Gases For complete parts list, please see Section 9 — P arts List on page 26. OM-CA3-2.2...
SECTION 6 — INSTALLATION 6-1 Installing Gun to Robot Figure 6-A Figure 6-B A. Installing Disc to Robot 1. Bring robot to service position. 2. Align the dowel in the wrist with the dowel hole in the insulating disc and fully seat the disc on the robot wrist. NOTE: Dowel not provided. 3. Install the disc to the robot with fasteners using the supplied tightening pattern (see Figure 6-A). IMPORTANT: Do not use the fasteners to pull the face of the insulating disc to the face of the robot wrist, as damage will occur. NOTE: Fasteners are not provided since the size varies by robot. 4. Torque to 45 in-lbs (5 Nm). Figure 6-C B. Installing Mounting Arm to Disc 1. Align dowel on mounting arm with the dowel hole in insulating disc and seat it by hand. 2. ...
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C. Installing Clutch or Solid Mount Clamp to Figure 6-E Figure 6-D Mounting Arm 1. Remove the fastener and the locking pin from the mounting arm. 2. Insert the clutch / solid mount stud into the mounting arm on the robot until it bottoms out. 3. Once the stud is fully seated in the mounting arm, reinstall the fastener and locking pin. I MPORTANT: The flat feature of the locking pin must interface with the flat feature on the clutch or solid mount stud to achieve proper locking and orientation as shown below in Figure 6-G, Figure 6-H and Figure 6-I (solid Solid Mount Shown Clutch Mount Shown mount shown). 4. Insert the 6 mm SHCS on the opposite side of the arm and Figure 6-F screw it into the locking pin. 5. Torque 6 mm SHCS to 60 in-lbs (7 Nm). For Solid Mount Models Only: 6. ...
Figure 6-J D. Installing Gun to Gun Mount 1. Loosen clamp screws in mounting clamp. 2. Fully insert gun into the clamp, aligning the key on the gun with the keyway on the clamp. 3. Tighten the 6 mm SHCS using a 5 mm Allen wrench to secure the gun in place. 6-2 Installing Gun to Wire Feeder 1. Plug gun into feeder and lock in place (see your feeder manual Figure 6-K for details). Connect external gas if required. 2. OPTIONAL: Connect voltage sense lead (see your feeder manual for details) on the replaceable unicable with the male connector on the power jumper cable. 3. FOR CLUTCH INSTALLATIONS: Connect clutch cable with either the provided connections (cut and splice required) or one of our jumper cables (sold separately and available only for select robot models). NOTE: Be sure to align any features to allow for proper installation. OM-CA3-2.2...
6-3 Installing Clutch Cable to Gun Figure 6-L 1. Connect cable supplied with clutch mount to the receptacle on the gun body. 2. Tighten securely by hand. 6-4 Connecting Wire Brake and/or Air Blast A. Wire Brake 1. Route wire brake air line to designated control valve in your facility (not provided). 2. 40-60 psi air supply required for proper operation. B. Air Blast 1. Route air blast air line to designated control valve in your facility (not provided). 2. 80-100 psi air supply required for proper operation. OM-CA3-2.2...
1. Pull slip-on nozzles off with a twisting motion. 1. Thread the retaining head / diffuser onto neck with a 5/8” (16 2. When installing the nozzle, ensure that it is fully seated. mm) wrench. 2. Torque to 80 in-lbs (9 Nm). IMPORTANT: DO NOT use pliers to remove or tighten the B. Changing the Contact Tip heavy duty retaining head / diffuser or scoring may result. 1. Thread the contact tip into the retaining head / diffuser. 2. Torque to 30 in-lbs (3.5 Nm). D. Changing the Neck Insulator 3. The Tregaskiss Tip Tool (part #450-18 for TOUGH LOCK heavy duty tips, or part # T-ALTOOL for AccuLock tips) or a pair of 1. Remove front-end consumables. weld pliers are the optimal tools for contact tip installation. 2. The neck insulator is pressed onto the neck by hand with the aluminum side towards the neck and the black insulation towards the nozzle. 3. Reinstall front-end consumables. OM-CA3-2.2...
7-2 Changing the Neck Figure 7-B 1. Remove front-end consumables (see section 7-1 Changing Consumables on page 16). 2. Remove liner (see section 7-4 Changing the Liner on page 19). 3. Using a 5 mm Allen wrench, loosen screw 1/4 turn to remove the neck. 4. Pull neck directly out of the connector housing. 5. Insert replacement neck into the connector housing, ensuring the key on the neck is lined up with the keyway on the gun. 6. Tighten screw to 60 in-lbs (7 Nm) using a 5 mm Allen wrench. 7. Install and trim liner if required. 8. Reinstall consumables. 7-3 Changing TOUGH GUN I.C.E.™ Components 1. Remove front-end consumables (see section 7-1 Changing Figure 7-C Consumables on page 16). 2. Remove screw and remove water line bracket. 3. Disconnect both water lines at quick connect couplers. OM-CA3-2.2...
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4. Loosen neck bolt (7-2 Changing the Neck on page 17). Figure 7-D 5. Remove TOUGH GUN I.C.E. components / neck assembly. NOTE: If existing clamping device on arm has 2 bolts, remove only the front bolt and snug the rear bolt. 6. Reinstall TOUGH GUN I.C.E. components / neck assembly. Figure 7-E 7. Tighten neck bolt to torque specification of 60 in-lbs (7 Nm). 8. Connect water lines with quick connect couplers. Figure 7-F 9. Fasten water line bracket with bolt (bracket and bolt included with TOUGH GUN I.C.E. assembly). NOTE: Ensure both bolts are tightened on the mounting clamp. 10. Reinstall front-end consumables. OM-CA3-2.2...
7-4 Changing the Liner ® Figure 7-G A. Changing QUICK LOAD Liner NOTE: Ensure power supply is off before proceeding. 1. Remove consumables (nozzle, contact tip and retaining head / diffuser) (see section 7-1 Changing Consumables on page 16). 2. Remove existing QUICK LOAD Liner by pulling it out from the Figure 7-H neck. 3. Insert the new QUICK LOAD Liner through the neck using the welding wire as a guide (short strokes will prevent kinking). 4. Once liner stops feeding, give it an extra push until it bottoms out in the liner retainer in the power pin to ensure it is inserted completely. Figure 7-I 5. Push liner back into gun and hold in place. Using liner gauge, trim liner to a 1/2" stick-out for gun lengths 6 feet and shorter, or 3/4” stick-out for gun lengths longer than 6 feet. HELPFUL HINT: Before cutting the liner with wire inside, mark the liner using the gauge and then pull the liner out beyond the end of the welding wire; then cut the liner and push it back into place securely. This will help with feeding the wire through the contact tip afterward. 6. Remove any burr that may obstruct wire feed. 7. Reinstall consumables onto neck. OM-CA3-2.2...
B. Changing QUICK LOAD Liner in the AutoLength System NOTE: Ensure power supply is off before proceeding. 1. Remove consumables (nozzle, contact tip and retaining head / diffuser) (see section 7-1 Changing Consumables on page 16). 2. Remove existing QUICK LOAD Liner by pulling it out from the neck. 3. Insert the new QUICK LOAD Liner through the neck using the welding wire as a guide (short strokes will prevent kinking). 4. Feed liner into the gun until it engages with the retainer inside the AutoLength Pin. Place the liner gauge onto the end of the QUICK LOAD Liner and press flush with the end of the neck. 5. Push the QUICK LOAD Liner into the gun until the liner will not go forward any further. NOTE: Liner will be pushed in by approximately one additional inch. 6. Using the liner gauge, trim the liner with a 1/2" stick-out for gun lengths 6 feet and shorter, or a 3/4” stick out for gun lengths longer than 6 feet. NOTE: After trimming, the liner will stick out of the neck by approximately 1-3/4”. This is normal, as the liner will be pushed back into the neck when the consumables are installed. 7. Feed wire through the MIG gun. 8. Reinstall consumables. 7-5 Changing the Power Pin or AutoLength™ Pin IMPORTANT: The thread-in two-piece power pin incorporates a taper to seat and lock the power pin into the rear handle block. Make sure power pin is tightened in the block with a wrench to ensure pin is secure and will not come loose. NOTE: The rear handle and screws do not have to be removed when installing the two-piece power pins.
7-6 Changing the Replaceable Unicable Figure 7-K 1. Remove nozzle, retaining head / diffuser and liner. 2. FOR CLUTCH MODELS ONLY: Disconnect external clutch cable from the clutch connector housing. 3. Loosen cable guide. Figure 7-L 4. FOR CLUTCH MODELS ONLY: Remove clutch connector housing and disconnect internal wiring (see Figure 7-L). 5. Turn connector counterclockwise to “UNLOCK” position (indicated by an “UNLOCK” position icon on the sticker) and slide away from the front housing to expose cable lock screw. Figure 7-M 6. Unlock power connection between the cable and front housing using a 5 mm Allen wrench (see Figure 7-M). OM-CA3-2.2...
7. Release cable assembly by turning a 1/4 turn counterclockwise Figure 7-N (see Figure 7-N). 8. Remove unicable. 9. Remove connector from cable assembly. Connector should be kept for the replacement unicable. 10. Remove power pin from unicable. 11. Discard old unicable and liner. NOTE: You will need to install a new liner to avoid discrepancies between the new unicable length and the length of the liner. 12. Reinstall power pin onto new cable. 13. Slide the connector that was removed from the old unicable over the front housing of the new unicable assembly. 14. FOR CLUTCH MODELS ONLY: Connect internal clutch wiring Figure 7-O and snap clutch connector housing into the connector. 15. FOR CLUTCH MODELS ONLY: Thread cable guide onto connector while holding the clutch connector housing in place. There is an undercut on the connector that allows the cable guide to hold this housing in place when installed properly. 16. Slide the unicable assembly onto the connector stud (on the back of the connector) and turn a 1/4 turn clockwise. Fasten the 5 mm SHCS to lock the unicable into place. 17. Slide the connector into place and turn a 1/4 turn clockwise to lock it into place. ...
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6. Unthread and remove the wire brake pushing unit to allow the wire guide to be released (see Figure 7-R). 7. Carefully slide the wire guide using the wire guide tool out of the gun body (see Figure 7-S). 8. Inspect for wear and swap for proper wire size as required. NOTE: 0.035”-0.045” with one guide, 0.052”-1/16” with another. Figure 7-Q 9. Reinstall appropriate wire guide using the wire guide tool with the flats oriented (see Figure 7-S). Align the hole with the pushing unit pin (see Figure 7-R). Thread in the pushing unit. 10. Reinstall power pin to feeder. 11. Reinstall consumables and neck, including the jump liner. 12. Feed wire through the gun. Figure 7-R 12. Reconnect the air lines and turn on the air pressure. 13. Disconnect drive rolls to allow wire to be pulled through the gun. Pull 6’-8’ out of the gun. NOTE: The wire should pull through the gun easily. If the wire binds, double check the wire guide to ensure it’s the proper size. Trim to proper stick out. 14. Activate wire brake via robot controller and attempt to pull additional wire out from gun. NOTE: The wire should no longer move. Figure 7-S OM-CA3-2.2...
8-2 Center of Mass Coordinates Standard Configurations - Clutch Mount 22 Degree Weight 316 mm TCP (405-22QC + CA2201) -0.50 mm 150.30 mm 6.47 mm 2.98 kg 350 mm TCP (405-22QCL + CA2202) -0.46 mm 165.80 mm -0.26 mm 3.09 kg 400 mm TCP (405-22QCL + CA2203) -0.48 mm 165.34 mm 44.19 mm 3.11 kg 45 Degree Weight 350 mm TCP (405-45QCL + CA4501) -0.50 mm 91.35 mm 5.73 mm 3.01 kg 400 mm TCP (405-45QCL1 + CA4502) -0.49 mm 92.12 mm...
SECTION 9 — PARTS LIST ITEM PART # DESCRIPTION See SP-CA3 Nozzle See SP-CA3 Contact Tip See SP-CA3 Retaining Head / Diffuser 405-22QC Neck, 22 degree, short length 405-22QCL Neck, 22 degree, medium length 405-45QC Neck, 45 degree, short length 405-45QCL Neck, 45 degree, medium length 405-45QCL1 Neck, 45 degree, long length 405-180QC Neck, 180 degree, medium length See SP-CA3 Neck, TOUGH GUN I.C.E.™ assembly Water Line Bracket (TOUGH GUN I.C.E. assembly 590-9 component) 590-8 Water Line Fittings, Male Water Line Fittings, Female + clamps (included in 810-10-5 ITEM 9) 590-4 TOUGH GUN I.C.E. Water Lines – 15 ft.
3. Extreme heat or duty cycle. 3. Replace with heavy duty consumables. See appropriate Spec Sheet for details. 4. Short contact tip life. 1. Contact tip size 1. Replace with proper size. 2. Electrode eroding contact tip. 2. Inspect and/or change drive rolls. 3. Exceeding duty cycle. 3. Replace with properly rated Tregaskiss MIG Gun. 5. Erratic arc. 1. Worn contact tip. 1. Replace contact tip. 2. Buildup inside of liner. 2. Replace liner, check condition of electrode. 3. Wrong tip size. 3. Replace with correct tip size. 4. Not enough bend in neck. 4. Replace with 45° neck. 6. Erratic wire feeding.
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8. Ruptured gas hose. 8. Repair or replace cable or line. 9. Control circuit loss. 9. See ‘Electrode does not feed’. 10. Worn, cut or missing o-rings. 10. Replace o-rings. 11. Loose fittings. 11. Tighten gun and cable connections to specified torque. See Section 7 — Replacement on page 16. 9. Gun running hot. 1. Exceeding duty cycle. 1. a. Replace with properly rated Tregaskiss MIG Gun. b. Decrease parameters to within gun rating. 2. Loose or poor power connection. 2. a. Clean, tighten or replace cable grounding connection. b. Tighten gun and cable connections to specified torque. See Section 7 — Replacement on page 16. 10. Liner is discolored. 1. Short circuit to electrode. 1. Isolate electrode reel from feeder and drive block. Consult ...
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